Structural element with at least a headlamp, and method for mounting such an assembly in a motor vehicle body

ABSTRACT

The invention concerns a motor vehicle assembly comprising a structural element and a headlamp for the vehicle, wherein the structural element is separate from the motor vehicle body and capable of being directly mounted thereon; the structural element and the headlamp have complementary arrangements for mounting the headlamp on the structural element while allowing the headlamp at least one degree of freedom along a specific direction; the headlamp and the car body have complementary stop arrangements defining a reference position for the headlamp along the specific direction; and elastic means are provided operating between the structural element and the headlamp for urging the headlamp along the specific direction countering the reaction force of the stop arrangements on the headlamp. The invention also concerns a method for mounting such an assembly into the car body, while defining reference position for the headlamp(s).

BACKGROUND OF THE INVENTION

The present invention relates to mounting of headlamps in motorvehicles.

Conventionally, a headlamp is mounted into a vehicle by being fixed byappropriate means onto bodywork parts of the vehicle. These fixing meansare generally designed to allow adjustment of the position off theheadlamp, in particular so that its glazing occupies the appropriateposition, in general flush and essentially in continuity, with respectto the bodywork surrounding the aperture formed therein in order toaccommodate the headlamp.

To set up the headlamp correctly in this position, it is known toprovide abutment means between the casing of the headlamp and ad hocarrangements of the bodywork, defining a reference position, and elasticmeans for forcing the headlamp into this reference position.

This setting-up principle, effective when the headlamp is mounteddirectly in the bodywork, is inapplicable, in contrast, when theheadlamp is mounted on a structural element which is for the purposefirst of all of accommodating the headlamp, then of being mounted intothe bodywork. In effect, even if a suitable referencing of the headlampis achieved with respect to this structural element, the manufacturingtolerances and mounting play intervening between the structural elementand the bodywork are in practice such that the headlamp will onlyfortuitously occupied the position sought with regard to the part of thebodywork adjacent to the headlamp. It is precisely with respect to thisbodywork part, however, that it is sought to position the headlampcorrectly.

BRIEF SUMMARY OF THE INVENTION

The present invention aims to remedy these limitations of the state ofthe art. It envisages, more precisely, making it possible to takeadvantage of a prior mounting of the headlamp onto a structural elementseparate from the bodywork and then affixed onto it, while providingcorrect positioning of the headlamp with respect to the bodyworkadjacent to it.

Hence the invention, according to a first aspect, proposes an assemblyof a vehicle structural element and of a headlamp of the vehicle,wherein

the structural element is separate from the bodywork of the vehicle andable to be affixed onto it,

the structural element and the headlamp possess matching arrangementsfor mounting the headlamp onto the structural element while leaving theheadlamp at least one degree of freedom along a given direction;

the headlamp and the bodywork possess matching abutment arrangementsdefining a reference position of the headlamp along said givendirection, and

an elastic means is provided, working between the structural element andthe headlamp so as to push the headlamp along said given directioncounter to the reaction force from the abutment arrangements on theheadlamp.

Preferred, but not limiting, aspects of the assembly according to theinvention are as follows:

said given direction is a direction which is generally horizontal andtransverse to the axis of the vehicle,

the matching abutment arrangements comprise an arrangement formed on awing part of the bodywork adjacent to an outer edge of a glazing of theheadlamp,

the matching mounting arrangements comprise hooking lugs formed on theheadlamp and interacting with hooking orifices formed in correspondingregions of the structural element,

second matching abutment arrangements are also provided, defining areference position of the headlamp along a second given direction andable to come into action when the matching mounting arrangements are putinto use,

the elastic means consists of a leaf spring mounted on the structuralelement.

the elastic means consists of a leaf spring made of the same material asthe structural element,

the structural element constitutes a vehicle front-face support andaccommodates a pair of left-hand and right-hand headlamps.

According to a second aspect, the invention proposes a method ofmounting an assembly comprising a vehicle structural element forming afront-face support and a pair of headlamps, the method comprising thefollowing steps:

mounting of the headlamps onto the structural element, leaving theheadlamps at least one degree of freedom along a given respectivedirection, each headlamp then being subjected to the action of arespective elastic means forcing it in said given respective direction,

mounting of the assembly thus obtained into the bodywork of the vehicle,the bodywork, in the course of this mounting, pushing the headlampscounter to the forces exerted by the respective elastic means so as tobring the headlamps into given reference positions.

Preferred, but not limiting, aspects of the above method are as follows:

said given respective directions are the same direction generallyhorizontal and transverse to the axis of the vehicle,

the forcing of the headlamps in the course of the stage of mounting theassembly is achieved by ar- rangements formed on wing parts of thebodywork in a way respectively adjacent to the outer edges of theglazing of the headlamps,

the stage of mounting the headlamps is carried out by translation andhooking along a direction different from each given respectivedirection,

the translation of each headlamp is carried out as far as an abutmentposition constituting a reference position of the headlamp along saiddifferent direction.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects, objects and advantages of the present invention willemerge on reading the description of a preferred embodiment thereof,given by way of non-limiting example and by reference to the attacheddrawings, in which:

FIG. 1 is a diagrammatic top view of an assembly formed from a part of astructural element of the vehicle and from a front headlamp,

FIG. 2 is a diagrammatic vertical sectional view illustratingarrangements for retaining and setting- up between the structuralelement and the headlamp, and

FIG. 3 is a diagrammatic view in perspective of the structural element.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, FIG. 1 represents a headlamp P whichconventionally includes a casing B closed by glazing G. This headlamp isintended to be fixed not onto arrangements belonging to the bodywork ofthe vehicle, but onto a separate structural element 10, called“front-face support”, intended to occupy the front region of the vehiclesubstantially over its entire width. Such a front-face support can beproduced from folded metal sheet, from injected plastic, from compositematerials, etc.

Such a front-face support 10 is illustrated diagrammatically in FIG. 3and in essence includes a central frame 11 intended for the fixing of aradiator of the vehicle and of associated equipment, as the case may be(motor-driven fan unit, etc.), and two lateral extensions 12G, 12D, thusforming frames of a sort, intended for mounting two left-hand andright-hand headlamps, which are not illustrated in this figure.

Various parts of the extension 12D intended for the headlamp P arerepresented diagrammatically in FIG. 1. These arrangements particularlycomprise an angle bracket 121 intended to lie beside the headlamp on itsinner side, a rear angle bracket 122, and intermediate parts 123, 124intended, as will be seen in detail later, to provide for the hookingand referencing of the position of the headlamp P.

Also represented in FIG. 1 is the region of the bodywork C adjacent tothe outer edge of the glazing G of the headlamp. This bodywork, at thislocation, possesses a re-entrant rim 20, extending substantially at aright angle with respect to the exterior of the bodywork, this rim 20being followed by another rim 21 further folded over about 90° in thesame direction.

The rim 21 defines an abutment intended to ensure that the headlamp,when it is mounted, occupies a suitable reference position along thetransverse axis Y. To that end, the casing B of the headlamp possessesan arrangement such as a member 30 an outer bearing edge 31 of which isintended to bear against the rim or positioning abutment 21.

In order to achieve this referencing, the casing of the headlamp takesup a force towards the outside of the vehicle, that is essentially fromthe right to the left in FIG. 1. This force is here exerted by a leafspring 50 which is mounted on the angle bracket 121 of the structuralelement 10 and which is applied against the side face 33 of the casing Bwhich is situated at the opposite end from the member 30. In the case inwhich the structural element 10 is produced from a material possessingadequate flexibility, such as a plastic or composite material, the leafspring 50 may advantageously be made from the same material as thisstructural element, which makes it possible to dispense with onecomponent.

By virtue of such a configuration, it is possible to mount the headlamponto a component of the vehicle separate from the bodywork itself, whileproviding suitable referencing of the position of the headlamp along Ywith respect to the bodywork in the region of the adjacent wing.

By reference now to FIGS. 2 and 3, a description will be given of themeans which make it possible, on the one hand, to hook the headlamp Ponto the front-face support 10, and, on the other hand, the associatedmeans which makes it possible to provide for suitable referencing of theposition of the headlamp P along the longitudinal direction of thevehicle (X axis).

These means comprise, on the one hand, a series of hooking lugs such as32 projecting rearwards from the casing B, each lug 32 possessing, atits free end, a step feature defined by a hooking tooth 321. Each lugcan be engaged in an associated aperture 1234 formed in an area 1233 ofthe intermediate part 123 (or 124), in order thus to retain the headlampin terms of a displacement frontward on the vehicle along the Xdirection.

Bosses such as 41, 42, 43, 44 are moreover formed either on the casingB, or on the foot of the glazing G, projecting rearwards, and are ableto bear along the X direction against arrangements such as 1231, 1232formed in the intermediate part 123 (124 respectively).

By dimensioning these members appropriately, it is thus possible for theheadlamp to be retained along X with no play.

It will be observed here that the apertures such as 1234 for the hookinglugs 32, as well as the bearing areas such as 1231, 1232 for the bossesformed on the casing or the glazing, are shaped and dimensioned in sucha way as to allow the displacement of the headlamp along the Y directionfor setting-up with the aid of or elastic piston means (the leaf spring50) when the assembly consisting of the front-face support 10 and of theheadlamps, and of the other members carried by the front-face support asappropriate, is mounted onto the vehicle.

In this context assembly preferably takes place:

by first of all mounting the headlamps P onto the front-face support 10,by involving the hooking lugs 32 (the headlamps are then set up in the Xdirection);

then by mounting this assembly into the vehicle, by the front or by therear, aligning the sides of the headlamps beside the region of thebearing edges 31 on the adjacent positioning abutments 21; this mountingpushes the headlamps counter to the forces exerted by the associatedsprings, in such a way as to set up the headlamps correctly along the Ydirection;

then, if necessary, by reinforcing the fixing of the headlamps in theposition thus obtained by the use of any appropriate adjustable fixingdevice.

If appropriate, the leaf spring 50 positioning and abutments 21 andbearing edges, 31 can also be made use of in order to providereferencing of the headlamp along the vertical direction (Z axis).

Needless to say, the present invention is not in any way limited to theembodiment described and represented, but the person skilled in the artwill be able to apply any variant or modification in accordance with itsspirit.

What is claimed is:
 1. An assembly of a vehicle structural element and aheadlamp of the vehicle, wherein: the structural element is separatefrom a bodywork of the vehicle and able to be affixed onto the bodywork,the structural element and the headlamp possess matching arrangementsfor mounting the headlamp onto the structural element while leaving theheadlamp at least one degree of freedom along a given direction; theheadlamp and the bodywork possess matching abutment arrangementsdefining a reference position of the headlamp along said givendirection, and an elastic means is provided, working between thestructural element and the headlamp so as to push the headlamp alongsaid given direction counter to a reaction force from the abutmentarrangements on the headlamp.
 2. An assembly according to claim 1,wherein said given direction is a direction which is generallyhorizontal and transverse to the axis of the vehicle.
 3. An assemblyaccording to claim 2, wherein the matching abutment arrangementscomprise an arrangement formed on a region of the bodywork adjacent toan outer edge of a glazing of the headlamp.
 4. An assembly according toclaim 1, wherein the matching mounting arrangements comprise hookinglugs formed on the headlamp and interacting with hooking orifices formedin corresponding regions of the structural element.
 5. An assemblyaccording to claim 4, further comprising second matching abutmentarrangements provided defining a reference position of the headlampalong a second given direction and able to come into action when thematching mounting arrangements are put into use.
 6. An assemblyaccording to claim 1, wherein the elastic means consists of a leafspring mounted on the structural element.
 7. An assembly according toclaim 1, wherein the elastic means consists of a leaf spring made of thesame material as the structural element.
 8. An assembly according toclaim 1, wherein the structural element constitutes a vehicle front-facesupport and accommodates a pair of left-hand and right-hand headlamps.9. A method of mounting an assembly having a vehicle structural elementforming a front-face support and a pair of headlamps, the methodcomprising: mounting the headlamps onto the structural element, leavingthe headlamps at least one degree of freedom along a given respectivedirection; subjecting each headlamp to an action of a respective elasticmeans forcing it in said given respective direction; and mounting theassembly thus obtained into the bodywork of the vehicle, the bodywork,in the course of this mounting, pushing the headlamps counter to theaction exerted by the respective elastic means so as to bring each ofthe headlamps into a given reference position; wherein the givenrespective directions are the same direction generally horizontal andtransverse to the axis of the vehicle and wherein the forcing of theheadlamps in the course of the stage of mounting the assembly isachieved by arrangements formed on regions of the bodywork in a wayrespectively adjacent to the outer edges of the glazing of theheadlamps.
 10. An assembly comprising: a bodywork of a vehicle having abodywork abutment; a front face support having at least one frame; avehicle headlamp having a vehicle abutment, the headlamp being disposedin the frame and adapted to move along at least a direction; and whereinthe headlamp is fixed by a spring relative to the bodywork and the frontface support, without being fixedly mounted to the bodywork, the springconfigured to apply force along the direction against the headlampdisposed in the frame of the front face support to cause the bodyworkabutment to frictionally engage the headlamp abutment at a referencepoint along the direction, and wherein the bodywork abutment comprises ashoulder formed from a reentrant rim extending substantially at a rightangle with respect to the bodywork and a parallel rim extendingsubstantially parallel to the bodywork and substantially at right anglesto the reentrant rim, and wherein the headlamp abutment comprising acomplementarily shaped member having a bearing edge configured to bearagainst the parallel rim.
 11. The assembly of claim 10, wherein thereference point is a point on the parallel rim and the direction isalong a horizontal axis that is transverse to a vehicle axis defined bythe headlamp.
 12. An assembly comprising: a bodywork of a vehicle havinga bodywork abutment; a front face support having at least one frame; avehicle headlamp having a vehicle abutment, the headlamp being disposedin the frame and adapted to move along at least a direction; and whereinthe headlamp is fixed by a spring relative to the bodywork and the frontface support, without being fixedly mounted to the bodywork, the springconfigured to apply force along the direction against the headlampdisposed in the frame of the front face support to cause the bodyworkabutment to frictionally engage the headlamp abutment at a referencepoint along the direction, and wherein the front face support comprisesat least one intermediate part having an aperture, and wherein theheadlamp comprises at least one lug having hooking tooth adapted, whenthe headlamp is disposed in the frame, to extend into the aperture andto prevent movement of the headlamp along a vehicle axis defined by theheadlamp.
 13. The assembly of claim 12, wherein the intermediate partcomprises a c-shaped member having a middle section including theaperture and a pair of end sections, the intermediate part furthercomprising a pair of flanges extending from the end sections toward oneanother, and wherein the headlamp includes a glazing, the glazingincluding a pair of intermediate bosses configured to engage the flangesof the intermediate part and to further prevent movement of the headlampalong the vehicle axis.
 14. The assembly of claim 13, wherein the framecomprises a lateral extension having an angle bracket configured to bearagainst an inner side of the headlamp and a rear angle bracketconfigured to bear against a back side of the headlamp adjacent to thereference point, and wherein the headlamp further comprises an end bossconfigured to engage the angle bracket to further prevent movement ofthe headlamp along the vehicle axis.
 15. The assembly of claim 14,wherein the spring is mounted on the angle bracket and is disposed tobear against a side face of the headlamp in a generally transversedirection transverse to the vehicle axis to cause the headlamp abutmentto frictionally engage the bodywork abutment at the reference point.